[0001] .This invention relates to improvements in the front end elements, i.e., the shadow
mask, mask frame, and inner shield, of a colour cathode ray tube (CRT).
[0002] A colour CRT, as shown in Figure 1, generally comprises a glass envelope 1, in-line
electron guns 3 emitting three electron beams 11, and a phosphor screen 5 containing
red, green, and blue phosphors which emit visible light when excited by the electron
beams 11. Electron guns 3 are located in the neck portion 2 of the envelope, while
the phosphors, arranged in vertical stripes of cyclically repeating colours, are coated
on the inner surface of the panel portion 4 of the envelope. Connecting neck 2 with
panel 4 is the funnel portion 12 of the envelope. Electron beams 11 are deflected
by magnetic fields produced by deflection yoke 10 surrounding a portion of the neck
2.
[0003] Near screen 5 is a shadow mask 6 having a plurality of vertically oriented rectangular
apertures (not shown). Shadow mask 6 is attached to a mask frame 7 supported within
the envelope by frame holders 8 which are releasably mounted on a plurality of panel
pins 13 embedded in side walls of panel 4. An inner shield 9, also attached to mask
frame 7, extends part of the way along funnel 12 toward electron guns 3, shielding
the electron beams 11 from the effects of terrestrial magnetism. After emission from
electron guns 3, electron beams 11 are accelerated, deflected by deflection yoke 10,
and converged. They then pass through the apertures of shadow mask 6 to bombard phosphor
screen 5, reproducing a colour image.
[0004] The front end elements of the colour CRT, i.e., shadow mask 6, mask frame 7 and inner
shield 9, are conventionally made of aluminum-killed steel because it is easily etched
(to make apertures) and easily formed into the necessary shapes for the front end
elements. "Killed" steel, as is known in the art, is steel which has, while in the
molten state, been caused to become quiet and free from bubbling by adding a strong
de- oxidising agent (such as aluminum) that combines with oxygen and minimises reaction
between oxygen and carbon during solidification. If the steel is incompletely de-
oxidised, after solidification the outside portion is distinctly different in constitution
from the interior of the ingot, and the material is known as "rimmed" steel).
[0005] Aluminum-killed steel is also easily coated with an oxide film, which helps to reduce
reflection of the electron beams. Although conventional front end elements are coated
with a black oxide film produced by a high temperature oxidation reaction, this oxide,
which may be alpha Fe
2O
3 and/or Fe
3O
4' adheres poorly to the base and occasionally spalls, since it contains voids.
[0006] With the recent emphasis on personal computer displays, teletext, and satellite transmission,
front end elements made of aluminum-killed steel, especially shadow masks, have been
unable to meet the high standards for resolution and "comfortable viewing (Comfortable
viewing is a term of art referring in part to the ability to discern fine characters
and images on the screen, i.e., high resolution, and in part to a brighter picture
produced by increasing beam current. Increased beam current, of course, increases
the amount of heat which must be dissipated by the front end elements).
[0007] When a colour CRT is energised, electron beam current raises the temperature of the
front end elements to anywhere from 303 K to 373 K. At those temperatures, the shadow
mask is deformed by thermal expansion, giving rise to what is called the "doming phenomenon".
When this occurs, a misalignment comes about between the apertures of the shadow mask
and the vertical phosphor stripes with which the apertures should be aligned. A colour
slippage phenomenon known as "purity drift" (PD) is the result. The smaller the apertures
in the shadow mask, and the more closely spaced they are, the more serious is the
colour slippage problem. Since high resolution or "comfortable viewing" colour CRT's
use shadow masks with small, closely spaced apertures, the large thermal epansion
coefficient of the aluminum-killed steel makes it impractical for use with these colour
CRT's.
[0008] To overcome this problem, it has been suggested (in Japanese Publication No. 42-25446,
Japanese Patent Disclosure No. 50-58977, and Japanese Patent Disclosure No. 50-68650)
that shadow masks and other front end elements be made of an iron-nickel alloy which
has a small coefficient of thermal expansion, such as Invar. These alloys have the
added advantage of being considerably harder than iron alone, so the closely- spaced
apertures used in high definition television (HDTV) receiver shadow masks will not
produce unacceptable weakening of the masks.
[0009] Although alloys of iron and nickel are desirable because of their hardness and their
small coefficient of thermal expansion, they have the disadvantage of low thermal
conductivity, causing them to retain heat. Consequently, these alloys still exhibit
an undesirable amount of colour slippage when used as shadow masks or other front
end elements in colour CRT's.
[0010] One object of the present invention is to improve the resolution and viewing comfort
of a colour CRT.
[0011] Another object of the invention is to reduce the purity drift of colour CRT- s.
[0012] Another object of the invention is to provide a front end element for a colour CRT
which has both a small coefficient of thermal expansion and high emissivity.
[0013] Another object of the invention is to provide such a front end element coated with
a black oxide layer which adheres well.
[0014] The invention accomplishes the above and other objects by forming front end elements
of a colour CRT from an alloy including iron and nickel as its principal components
and then oxidising this base alloy to coat its surface with a black oxide layer consisting
essentially of a spinel-type oxide. When used in this specification, the term spinel-type
oxide refers to a compound with the general formula J
xQ
(3-x)O
4, where x is a positive number less than 3. In the present invention, J is nickel
and Q is iron, so that the black oxide layer coating the iron-nickel base has the
formula Ni
xFe
(3-x)O
4.
[0015] A colour CRT front end element of this kind has a small coefficient of thermal expansion
(because the base alloy includes iron and nickel as its principal components), yet
is a good heat radiator because of the black oxide layer integrally formed on the
base. The low thermal conductivity of iron-nickel alloys, a property which causes
them to retain heat, is compensated by the excellent heat radiation characteristics
of the black oxide layer. As a result, when a shadow mask or another front end element
is made in accordance with this invention, the amount of doming caused by the rise
in temperature during use, and the colour slippage that accompanies misalignment between
the tiny apertures in the shadow mask and the phosphor stripes on thescreen, are both
reduced to a considerable degree. Therefore, a colour CRT can be produced with the
small closely spaced apertures necessary for high resolution and capable of using
the high beam current needed for comfortable viewing.
Figure 1 is a sectional view of a colour CRT which may incorporate the present invention.
Figure 2 is a sectional view of a front end element of the colour CRT shown in Figure
1.
[0016] The preferred embodiment of the invention will now be described in connection with
a shadow mask; however, the invention applies equally well to any front end element
of a colour CRT. The preferred iron-nickel alloy from which to form the shadow mask
contains from 30 to 40% by weight of nickel, and the remainder either iron with traces
of other components or up to 7% by weight of cobalt and the rest iron, with traces
of other components. (Whenever a composition is described herein by percentages of
its components, the percentages are by weight, unless otherwise specified). The trace
components may be, for example, silicon, manganese, phosphorous, sulfur, chromium,
aluminum, copper, zirconium and titanium. Without cobalt, the alloy is known as Invar;
with cobalt, with alloy is known as super Invar.
[0017] As shown in Figure 2, a shadow mask 6 manufacture in accordance with this invention
includes a black oxide layer 14 on both surfaces of the base 15.
[0018] In order to manufacture such a shadow mask, an ingot of Invar is prepared having
as its principal components 36% nickel and the remainder iron, along with traces of
carbon, slicon, manganese, phosphorous, sulfur, chromium, aluminum, copper, zirconium
or titanium. This ingot is annealed and formed by repeated cold working into a sheet
of thickness 0.15mm. A flat mask with a plurality of rectangular apertures is then
prepared by etching this sheet in a well-known manner using photoresist. The sheet
is coated with the photosensitive material, exposed, developed and then chemically
etched. After the flat mask is washed and sheared, it is annealed at 1423 K in a vacuum
and pressed into the spherical shaped of a shadow mask.
[0019] The mask is oxidised in an atmosphere of 25% oxygen and 75% nitrogen at a temperature
of 873 K, causing the formation of an integral black oxide layer on its exposed surfaces.
The black oxide layer formed integrally on the surface of the base alloy is a spinel-type
oxide with the formula Ni
xFe
(3-x)O
4, where x is a positive number less than 3, and when super Invar is used, having cobalt
solid-dissolved in it. The concentration of nickel in this black oxide layer may vary
with depth, a higher concentration generally occurring near the interface between
the base and the oxide layer and a lower concentration occurring at the surface of
the material. During oxidation, nickel atoms diffuse inwardly away from the surface,
while iron atoms (and cobalt atoms, if present) diffuse toward the surface. Under
appropriate conditions, however, a uniform nickel distribution can be obtained. In
addition to the spinel-type oxide (and solid-dissolved cobalt), minute amounts (less
than 1% by weight) of the trace elements mentioned above, which are unavoidably contained
in the base alloy, may also be present in the black oxide layer. It is believed that
the growth rate of the oxide layer may be controlled by controlling the amounts of
these trace elements in the base alloy, because they substitute for nickel in the
black oxide layer.
[0020] A layer of red iron oxide (alpha Fe
20
3) having a perovskite structure may be formed on the surface of the spinel-type oxide,
but it is extremely thin and does not affect the emissivity of the black oxide layer.
[0021] When the adhesion of the black oxide layer to the base is tested by an adhesive tape
peeling test, there is no peeling of the black oxide layer from the base. The adhesive
tape peeling test is peformed by first bending the element to a 90° angle, then straightening
it, and then applying adhesive tape and peeling it off by hand. Adhesion is particularly
good in an oxide of the formula Ni
xFe
(3-x)O
4 when x is in the range of 0.03 to 1.5, inclusive.
[0022] When a shadow mask produced in this way is used in a colour CRT, a stable image is
obtained. Furthermore, measurements of the value of purity drift have been made; these
measurements confirm that the purity drift have been made; these measurements confirm
that the purity drift obtained with this invention is considerably smaller than that
obtainable with a conventional shadow mask. Purity drift is measured by projecting
an electron beam through an aperture of a shadow mask and onto the phosphor coated
screen, then measuring the displacement of the electron beam projection, due to thermal
expansion of the shadow mask, from the ideal position of the projection. With conventional
shadow masks, a typical value of purity drift is 120 um, whereas the purity drift
available with a shadow mask manufactured in accordance with this invention is less
than 90 um. Moreover with the present invention the time necessary to recover from
transient purity drift is cut in half.
[0023] If the iron-nickel alloy includes 5% to 10% chromium, it may be more easily formed
into a shadow mask (or other front end element), because its yield strength is decreased.
If an iron-nickel alloy including 5% to 10% chromium is used, the black oxide layer
will be composed of a spinel-type oxide which has chromium substituted for part of
the nickel in the formula Ni
xpe(
3-x)
04'
[0024] When the thickness of the black oxide layer is lessthan about 10 um (for example
1 um) it is a dense black with good heat radiation characteristics. The emissivity
of the black oxide layer has been found to be 0.5 (compared with the emissivity of
a perfect black body, which is 1.0).
[0025] Of course, this invention is applicable to all front end elements of the colour CRT,
such as the mask frame and the inner shield. If these elements are also made of an
iron-nickel alloy and coated with- the black oxide layer of this invention, the heat
developed in the shadow mask by electron beam current is conducted to the mask frame
and the inner shield and quickly radiated from these elements.
[0026] Although illustrative embodiments of the present invention have been described in
detail with reference to the accompanying drawings, it is to be understood that the
invention is not limited to those precise embodiments and that various changes and
modifications may be effected therein by one skilled in the art without departing
from the scope or spirit of the invention.
1. A front end element for colour cathode ray tube comprising:
a base consisting of an alloy having iron and nickel as its principal components;
and
a black oxide layer formed integrally on said base, said black oxide layer consisting
essentially of a spinel-type oxide including iron and nickel.
2. A front end element as claimed in claim 1 wherein said spinel-type oxide further
includes solid-dissolved cobalt,
3. A front end element as claimed in claim 1 or claim 2 wherein said spinel type oxide
has the formula NixFe(3-x)O4, where x is a positive number less than 3.
4. A front end element as claimed in claim 3 wherein x is in the range from 0.03 to
1.5 inclusive.
5. A front end element as claimed in claim 1 wherein said alloy is Invar.
6. A front end element as claimed in claim 2 wherein said alloy is super Invar.
7. A front end element as claimed in claim 1 or claim 2 wherein said black oxide layer
is less than 10 um in thickness.
8. A front end element as claimed in claim 3 wherein said front end element comprises
a shadow mask.
9. A colour cathode ray tube comprising an envelope (1) having a neck portion (2)
at one end and a panel portion (4) at another end, electron gun means (3) in said
neck portion for emitting an electron beam, a phosphor screen (5) on an inner surface
of said panel portion to emit light upon bombardment by the electron beam, a shadow
mask (6) having a plurality of apertures, a mask frame (7) supporting said shadow
mask at a predetermined distance from said phosphor screen, and an inner shield (9)
attached to said mask frame to shield the electron beam from magnetic flux, characterised
in that at least one of said shadow mask (6), said mask frame (7) or said inner shield
(9) comprises:
a base consisting of an alloy having iron and nickel as its principal components;
and
a black oxide layer formed integrally on said base, said black oxide layer consisting
essentially of a spinel-type oxide having the formula NixFe(3-x)O4, where x is a positive number less than 3.
10.. A colour cathode ray tube according to claim 9 wherein said spinel-type oxide
further includes solid-dissolved cobalt.